Single Product Model for Transmission Design & Analysis RomaxDesigner

About this Presentation Aims of the presentation Modelling the components: shafts bearings gears Assembling the gearbox Defining the loads and powers Running the analysis Review of the results and further RomaxDesigner capabilities Copyright © Romax Technology Limited 2000 - 2005

Introduction Aims of this presentation are to show how: To model an existing transmission in just one day To analyze the model for shaft, bearing and gear performance and life To use the analysis results to optimize an existing design Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Key Stages for Creating a RomaxDesigner Model Definition of components Mounting the gears on to shafts Definition of gearbox internal geometry Powerflow definition and analysis Review of results Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission RomaxDesigner Modelling stages: Definition of components Mounting the gears on to shafts Definition of gearbox internal geometry Powerflow definition and analysis Review of results Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission The first step is to create a shaft by simply selecting it from the menu: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Specify the approximate shaft outer dimensions: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission To create shaft sections of different sizes, use the cutter icon to define steps: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Specify the dimensions of each section including any tapers and bores if needed: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission The user need only input the geometry RomaxDesigner will generate static and dynamic models from this data instantaneously Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission RomaxDesigner automatically generates a solid model and 3-D view for easy visualization: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission To add bearings, select the bearing icon and click at the approximate position: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission RomaxDesigner has complete bearing database catalogues for SKF and FAG to choose from - as well as a Custom specification option: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission View the details of a range of bearings and accept the most suitable: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Every bearing is a fully specified engineering object ready for analysis: Virtual Component has : - Dimensions - Engineering Properties Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Specify its exact position on the shaft, and conditions such as axial constraints and pre-load: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Repeat the procedure to add further bearings: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission The 3-D view is updated automatically: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission To add gear pairs there are two options for defining gear geometry: Concept gear pair Basic gear data required for the calculation of forces on the shafts and bearings Detailed gear pair Requires additional macro-geometry data for gear rating Concept - quick check, allows fast progress with confidence that can detail later if the model looks promising FOR RATIO AND CALCULATION OF LOADS ON THE SHAFTS Detail - the full model, mainly an automated generation, the exact design and all attendant details required for full analysis are specified uniquely by just a few variables - once again rapid results DETAILED DESIGN AND RATING TO ISO 6336 AND AGMA 2001 Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Create a new concept gear pair: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Detail the concept pair if full analysis results are required: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission A completed detailed gear pair: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Mount the gear on the shaft with the gear icon: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Create and connect more gears to complete the shaft: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission The completed solid model of the shaft in 3-D: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission RomaxDesigner automatically produces a static model: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission And a dynamic model to completely simulate the behaviour of the shaft: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission RomaxDesigner Modelling Areas: Definition of components Mounting the gears on to shafts Definition of gearbox internal geometry Powerflow definition and analysis Review of results Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Modelling Overview Gear mounting definition There are four options for defining gear mounting in the model: Integral with shaft The gear is manufactured into the shaft Rigidly mounted to shaft The gear is permanently attached to the shaft Synchronizer or clutch connection The gear is free to rotate on the shaft unless the synchroniser/clutch is engaged Free Rotation The gear is free to rotate on the shaft Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Selection of gear mounting method: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Define the details of the gear blank for inertia calculations: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission RomaxDesigner Modelling Areas: Definition of components Mounting the gears on to shafts Definition of gearbox internal geometry Powerflow definition and analysis Review of results Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Once the other shafts have been generated, their relative positions need to be specified: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission The completed gearbox: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission The completed solid model is ready for analysis: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission RomaxDesigner Modelling Areas: Definition of components Mounting the gears on to shafts Definition of gearbox internal geometry Powerflow definition and analysis Review of results Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions Add input and output power loads with the power load icon: Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions Define the time and clutch/synchro for each speed: Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions Define the loads for each speed: Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions The completed duty cycle with six defined speeds, ready to run: Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions The duty cycle results on all components are calculated in under a minute on a standard PC: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission RomaxDesigner Modelling Areas: Definition of components Mounting the gears on to shafts Definition of gearbox internal geometry Powerflow definition and analysis Review of results Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Review of Results RomaxDesigner calculates complete duty cycle results, in under a minute, on a standard PC The results for each load case include: Forces, moments, displacements and stresses for all shafts Deflections, tilts and displacements on all bearings Mesh misalignment for all gear meshes Life rating for all bearings and gears including misalignment effects Copyright © Romax Technology Limited 2000 - 2005

Review of Results The results for a single load case will be examined first: Shaft loadings and deflections leading to bearing rating and gear mesh misalignment Then the cumulative effect of the duty cycle will be shown This gives a final assessment of gear and bearing performance for the specified duty cycle Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case The input shaft forces in 1st speed in the x-direction: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case The input shaft shear force diagram in 1st speed in the x-z plane: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case Input shaft moments in 1st speed in the x-z plane: Moment from the bearing arises from the calculated tilt stiffness Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case Input shaft displacements in 1st speed in the x-direction: The bearing displacement is non-zero Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case Input shaft bending stresses in 1st speed: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case Bearing results showing the life, as well as the relative and absolute displacements: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case Bearing results showing the bearing stiffnesses: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case Shaft deflections are converted into gear mesh misalignment: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case The life rating for the gear pair is then calculated to ISO 6336 or AGMA 2001: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case The user can choose to include the effect of misalignment in the gear rating: Copyright © Romax Technology Limited 2000 - 2005

Duty Cycle Results For each component, the duty cycle result includes a contribution from each load case: Copyright © Romax Technology Limited 2000 - 2005

Duty Cycle Results Complete ISO life and the Adjusted life (which includes the effect of misalignment on bearings): Copyright © Romax Technology Limited 2000 - 2005

Duty Cycle Results Also duty cycle results for the gear pair : Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission RomaxDesigner Modelling Areas: Definition of components Mounting the gears on to shafts Definition of gearbox internal geometry Powerflow definition and analysis Review of results Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Further Analysis (i) Examples of additional work possible using the RomaxDesigner software: The influence of Housing Stiffness on the system deflections The misalignment of synchronized gears mounted on needle roller bearings Stress concentration factors and shaft fatigue analysis. - Defining gear trains including reverse - - The effect of housing stiffness derived from FEA data - How is the cycle more detailed? (MORE LOADCASES, E.G. 5TH SPEED 100%, 80% ETC. TORQUE). Conclusion needed. CONCLUSIONS SHOULD BE: Modeling OF THE COMPLETE GEARBOX IN LESS THAN 1 DAY DUTY CYCLE ANALYSIS OF GEARBOX IN LESS THAN 1 MINUTE WORLD-LEADING ANALYSIS IN AN EASY-TO-USE INTERFACE SPEED-OF-USE ALLOWS DESIGN Optimization Copyright © Romax Technology Limited 2000 - 2005

Further Analysis (ii) Examples of additional work possible using the RomaxDesigner software: A more detailed duty cycle, e.g. for different driving styles and conditions Gear micro-geometry definition and transmission error calculation Synchronizer sizing and simulation. Copyright © Romax Technology Limited 2000 - 2005

Further Analysis (iii) Examples of additional work possible using the RomaxDesigner software: Driveline dynamic analysis and NVH Perpendicular shafts, hypoid, spiroid and bevel gears In-depth analysis of bearings. Copyright © Romax Technology Limited 2000 - 2005

Conclusions RomaxDesigner allows: Modelling of a complete gearbox … in less than 1 day Duty cycle analysis of a gearbox … in under 1 minute World-leading analysis in an easy-to-use interface This speed-of-use allows rapid iterative design optimization for the first time Copyright © Romax Technology Limited 2000 - 2005

Your Next Step! Thank you for reviewing RomaxDesigner. You may now wish to: Start using RomaxDesigner Take one of the Romax in-depth training courses on transmissions, or gear design using RomaxDesigner (email us - see next slide) Contact Romax for more details on Romax software solutions (see next slide) Copyright © Romax Technology Limited 2000 - 2005

For more information contact: Romax Technology Limited Rutherford House Nottingham Science and Technology Park Nottingham England, NG7 2PZ Tel: +44 (0)115 951 8800 Fax: +44 (0)115 951 8801 e-mail: info@romaxtech.com http://www.romaxtech.com